HELP Vol. 04 – Let’s Create a Thick Alignment Film!
A university professor recently asked:
“Can NANON create a PVDF alignment film about 500μm thick?”
Since none of the team members had previously spun such a thick alignment film, we decided on this as our theme: “Creating a Thick Alignment Film.”
■ Asking Manager Nogami for HELP!
Is it difficult to make a thick alignment film?
The thicker it gets, the more difficult it becomes because the deposited fibers charge up and reduce the collector’s efficiency.
How long will it take to create a 500μm film?
It depends on the material, but for 500μm, conduct a 10-hour test first. Set the FEED RATE to 2ml and use a 22G needle.
■ Spinning Test Parameters
- Voltage: 20kV
- Feed Rate (FR): 2ml/h
- Distance: 150mm
- Needle: 22G
- Cleaning Frequency: Once every 10 minutes
■ Test Results after 10 Hours
Calculation for 500μm: 500 ÷ 9.2 = 54.4 hours.
Spinning rate: 92μm/h.
Alright! Let’s spin for 54 hours!
That’s the calculation, but Manager Nogami mentioned that the thicker it gets, the harder it is for the fibers to deposit. So, I think we should spin for more than 54 hours.
Alright, let’s aim for 60 hours and officially begin the full-scale spinning experiment!
Today is Wednesday! If we start right away, we can take a break over the weekend and finish by next Tuesday!
Is it okay to continue spinning on fibers that have been left for two days? I’m worried that the condition of the fibers might change and affect the spinning process.
As Gao said, I don’t recommend spinning continuously after leaving it for a few days.
Understood. Then let’s start first thing Monday morning.
We aim for a 60-hour continuous spinning test to account for fiber deposition issues as the thickness increases.
Next Steps:
- Day 1: Monitor for 10 hours and refill the solution as needed.
- Day 2: Address any anomalies, such as fiber scattering due to reduced collector efficiency.
As the fiber thickness increases, the gap between the drum collector and the cover may narrow, causing the cover to rub against the fibers.
We need to visually check the gap and gradually adjust the cover position on the drum collector to make it higher.
- Day 3
- Day 4
- Final day
■ Conclusion
Film Thickness: 500 μm
Spinning Time: 52 hours
Solution Amount: 104 ml
Key Points for Producing Thick Nanofibers:
- Adjust the position of the spinneret and cover during the spinning process.
- Utilize the cleaning mechanism to prevent nozzle clogging.
Our nanofiber electrospinning device, NANON, is equipped with an automatic cleaning mechanism that cleans the nozzle at a preset frequency, making it highly effective for continuous spinning!
Producing thick nanofibers is a challenging and meticulous process, but it’s a technology unique to our company! Especially when it comes to creating A4-sized alignment films—only MECC can do it. Make sure to remember that!
Our NANON is designed for stable, long-duration spinning. If you’re considering alignment films or thick nanofiber spinning, feel free to reach out to us anytime!